Light-emitting device

ABSTRACT

A light-emitting device, includes a substrate structure, including a base portion having a surface and a plurality of protrusions regularly formed on the base portion; a buffer layer covering the plurality of protrusions and the surface; and III-V compound semiconductor layers formed on the buffer layer; wherein one of the plurality of protrusions includes a first portion and a second portion formed on the first portion and the first portion is integrated with the base portion; and wherein the base portion includes a first material and the first portion includes the first material.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional application of U.S. patent applicationSer. No. 16/397,775, filed on Apr. 29, 2019, which claims priority tothe benefit of Taiwan Application Serial Number 107114617 filed on Apr.30, 2018, and the entire contents of which are hereby incorporated byreference herein in its entirety.

BACKGROUND Technical Field

The present disclosure relates to a light-emitting device, morespecifically, to a light-emitting device including a substratestructure.

Description of the Related Art

The light-emitting diodes (LEDs) have been widely used in solid-statelighting. The LEDs have the characteristics of low power consumption andlong life time compared with conventional incandescent lamp andfluorescent lamp. Therefore, the LEDs have gradually replacedconventional light source and are applied to various fields, such astraffic lamps, backlight modules, streetlights, medical equipment andthe like.

SUMMARY

A light-emitting device, includes a substrate structure, including abase portion having a surface and a plurality of protrusions regularlyformed on the base portion; a buffer layer covering the plurality ofprotrusions and the surface; and III-V compound semiconductor layersformed on the buffer layer; wherein one of the plurality of protrusionsincludes a first portion and a second portion formed on the firstportion and the first portion is integrated with the base portion; andwherein the base portion includes a first material and the first portionincludes the first material.

A method of manufacturing a light-emitting device, including: providinga substrate structure including a base portion and wherein the baseportion includes a surface; performing a patterning step to form aplurality of protrusions, wherein the plurality of protrusions arearranged on the surface of the base portion; forming a buffer layer onthe surface of the base portion by physical vapor deposition, whereinthe buffer layer covers the protrusions; and forming III-V compoundsemiconductor layers on the buffer layer; wherein one of the pluralityof protrusions has a height not greater than 1.5 μm; and wherein thelight-emitting device has a full width at half maximum (FWHM) of smallerthan 250 arcsec in accordance with a (102) XRD rocking curve.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A and 1B show a light-emitting device in accordance with a firstembodiment of the present application.

FIGS. 2A and 2B show a light-emitting device in accordance with a secondembodiment of the present application.

FIGS. 3A and 3B show a light-emitting device in accordance with a thirdembodiment of the present application.

FIGS. 4A and 4B show top views of a substrate structure of thelight-emitting device in accordance with different embodiments of thepresent application, respectively.

FIGS. 5A and 5B show cross-sectional views of a protrusion of thelight-emitting device in accordance with different embodiments of thepresent application, respectively.

DETAILED DESCRIPTION OF THE EMBODIMENTS

To better and concisely explain the disclosure, the same name or thesame reference number given or appeared in different paragraphs orfigures along the specification should has the same or equivalentmeanings while it is once defined anywhere of the disclosure.

FIGS. 1A and 1B show a light-emitting device 100 in accordance with afirst embodiment of the present application. FIG. 1A shows across-sectional view of the light-emitting device 100. As shown in FIG.1A, the light-emitting device 100 includes a substrate structure 102, abuffer layer 104 formed on the substrate structure 102, a firstsemiconductor layer 106 formed on the buffer layer 104, a light-emittingstructure 108 formed on the first semiconductor layer 106 and a secondsemiconductor layer 110 formed on the light emitting structure 108. Thefirst semiconductor layer 106, the light emitting structure 108 and thesecond semiconductor layer 110 include III-V compound semiconductor,such as aluminum gallium indium nitride (In_(x)Al_(y)Ga_(1-x-y)N, 0≤x≤1,0≤y≤1). The light-emitting structure 108 can be a single heterostructure(SH), a double heterostructure (DH), a double-side doubleheterostructure (DDH), or a multi-quantum well, MQW). As shown in FIG.1A, a direction T1 indicates the growth direction of the light-emittingstructure 108. The light-emitting structure 108 generates radiation. Inthis embodiment, the radiation includes light. The light can be visibleor invisible. The light has a dominant wavelength which can be between250 nm and 500 nm. In this embodiment, the light-emitting device 100further includes a first electrode 120 and a second electrode 130. Thefirst electrode 120 is formed on the first semiconductor layer 106 andelectrically connects to the first semiconductor layer 106. The secondelectrode 130 is formed on the second semiconductor layer 106 andelectrically connects to the second semiconductor layer 106.

Referring to FIG. 1B and FIG. 1A, FIG. 1B is a partial enlarged view ofthe substrate structure 102 of FIG. 1A. The substrate structure 102includes a base portion 102 b and a plurality of protrusions 102 c. Thebase portion 102 b has a surface 102 a. In one embodiment, the thicknessof the base portion 102 b is not less than 100 μm. In one embodiment,the thickness of the base portion 102 b is not more than 300 μm. Theplurality of protrusions 102 c is arranged in a two-dimensional array onthe surface 102 a of the base portion 102 b, and the arrangement of theplurality of protrusions 102 c can be regular or irregular. Each of theprotrusions 102 c includes a first material and the base portion 102 bincludes a second material. The refractive index of the first materialis smaller than the refractive index of the second material.Specifically, the refractive index of the first material of theprotrusion 102 c at the dominant wavelength is smaller than therefractive index of the second material of the base portion 102 b at thedominant wavelength. In one embodiment, at the dominant wavelength, thedifference between the refractive index of the first material of theprotrusion 102 c and the refractive index of the second material of thebase portion 102 b is greater than 0.1; in another embodiment, thedifference is greater than 0.15; and still in another embodiment, thedifference is between 0.15 and 0.4 (both inclusive). The material of thebase portion 102 b can be sapphire, and the surface 102 a is c-planewhich is suitable for epitaxial growth. The material of each of theprotrusions 102 c can be silicon dioxide (SiO₂). The three-dimensionalshape of the protrusion 102 c includes a dome, a cone, or a pyramid. Thecone includes a truncated cone and the pyramid includes a polygonalpyramid or a truncated pyramid. In the embodiment, the three-dimensionalshape of the protrusion 102 c is a cone, wherein the protrusion 102 c issubstantially triangular in the cross-sectional view of thelight-emitting device. The buffer layer 104 is conformally formed on theplurality of protrusion 102 c and the surface 102 a. Specifically, thebuffer layer 104 has a top surface 1041 opposite to the base portion 102b. The top surface 1041 includes a first portion 1042 and a secondportion 1043 connected to the first portion 1042. The first portion 1042covers the surface 102 a. The second portion 1043 covers the pluralityof protrusions 102 c. In the cross-sectional view of the light-emittingdevice 100, a recess 111 is defined between the first portion 1042 andthe second portion 1043. In one embodiment, the buffer layer 104comprises aluminum nitride (AlN). In one embodiment, the thickness ofthe buffer layer 104 is greater than 5 nm; in another embodiment, thethickness is not more than 50 nm; and still in another embodiment, thethickness is between 10 nm and 30 nm (both inclusive). If the thicknessof the buffer layer 104 is less than 5 nm, the defect density of theepitaxial layers (e.g. the first semiconductor layer 106) subsequentlygrown thereon becomes high and the epitaxial quality of thelight-emitting device is disrupted. If the thickness of the buffer layer104 is more than 50 nm, for example, an AlN buffer layer with athickness of more than 50 nm, the dominant wavelengths of the pluralityof light-emitting devices epitaxially grown on the same wafer areinconsistent with each other. As shown in FIG. 1B, an included angle θis between the surface 102 a and the side surface of one protrusion 102c or each of the protrusions 102 c. In one embodiment, θ is not greaterthan 65 degrees; in another embodiment, θ is not more than 55 degrees;and still in another embodiment, θ is between 30 and 65 degrees (bothinclusive). In one embodiment, two included angles θ are between thesurface 102 a and the side surface of one protrusion 102 c or each ofthe protrusions 102 c and θ are not greater than 65 degrees; in anotherembodiment, θ are not greater than 55 degrees; and still in anotherembodiment, θ are between 30 and 55 degrees (both inclusive). In oneembodiment, the two included angles θ of one protrusion 102 c or the twoincluded angles θ of each protrusion 102 c have the same degrees ordifferent degrees. Each protrusion 102 c has a height H and a bottomwidth W. In the present embodiment, the height H is not more than 1.5and in another embodiment, the height H is between 0.5 μm and 1.5 μm(both inclusive). The bottom width W is not less than 1 μm, and inanother embodiment, the bottom width W is between 1 μm and 3 μm (bothinclusive). In one embodiment, the ratio of the height H to the bottomwidth W is greater than 0 and not more than 0.5. In another embodiment,the ratio of the height H to the bottom width W is between 0.4 and 0.5(both inclusive). As shown in the figures, the arrangement of theprotrusions 102 c has a period P. In one embodiment, the protrusion 102c has a vertex, and the vertex is the part of the protrusion 102 c whichis closest to the light-emitting structure 108 along the direction T1.The period P is defined as the distance between the vertices of twoadjacent protrusions 102 c. In this embodiment, the cross-section of theprotrusion 102 c is substantially triangular, and the period P isbetween 1 μm and 3 μm (both inclusive). In one embodiment, the heightH=1.2 μm±10%; the bottom width W=2.6 μm±10%; the period P=3.0 μm±10%. Inanother embodiment, the height H=0.9 μm±10%; the width W=1.6 μm±10%; theperiod P=1.8 μm±10%. In another embodiment, H=1 μm±10%; W=1.5 μm 10%;P=1.8 μm±10%. In another embodiment, the height H=1.2 μm±10%, the widthW=2.6 μm±10%; and the period P=3.0 μm±10%. In one embodiment, x-raydiffraction (XRD) analysis is used to investigate the materialcharacteristics of the epitaxy layers of the light-emitting device 100.The light-emitting device 100 has a FWHM (full width at half maximum)value of smaller than 250 arcsec in accordance with a (102) XRD rockingcurve. In one embodiment, the FWHM value is not smaller than 100 arcsec.Light emitted from the light-emitting structure 108 is reflected and/orrefracted due to the plurality of protrusions 102 c formed on thesurface 102 a of the substrate structure 102 so that the light emittingefficiency of the light-emitting device 100 is improved. Moreover, inthis embodiment, because of the substrate structure 102 coupled with thebuffer layer 104, the quality of the semiconductor layers and thelight-emitting structure 108 grown thereon is improved.

As shown in FIG. 1A, a method for fabricating a light-emitting device100 in accordance with an embodiment of the present applicationincludes: providing a substrate structure 202 including the base portion202 b and the plurality of protrusions 202 c formed thereon, wherein thebase portion 202 b has a surface 202 a; and performing a patterning stepto form the plurality of protrusions 202 c. The patterning step includesforming a precursor layer (not shown) on the surface 102 a by, forexample, physical vapor deposition (PVD), and then removing a portion ofthe precursor layer. The method of removing the portion of the precursorlayer includes dry etching or wet etching. The portion of the precursorlayer is removed and then the other portion of the precursor layer kepton the surface 202 a forms the plurality of protrusions 202 c separatedfrom each other. In the embodiment, the protrusion is substantiallytriangular in the cross-sectional view. The plurality of protrusions 202c is arranged in a two-dimensional array on the surface 202 a of thebase portion 202 b, and the arrangement of the plurality of protrusions202 c can be regular or irregular. The method for fabricating thelight-emitting device 100 in accordance with an embodiment of thepresent application further includes forming the buffer layer 104 on thesurface 102 a of the base portion 202 b and covering the protrusions 202c. The buffer layer 204 comprises aluminum nitride (AlN). The method offorming a buffer layer 104 includes physical vapor deposition (PVD). Themethod of fabricating the light-emitting device 100 further includesforming the first semiconductor layer 206, the light-emitting structure208 and the second semiconductor layer 210 by epitaxial growth such asmetal organic chemical vapor deposition (MOCVD). The method of epitaxialgrowth includes, but is not limited to, MOCVD, hydride vapor phaseepitaxial (HVPE), or liquid-phase epitaxy (LPE).

As shown in the embodiment of FIG. 1A, the light-emitting device 100further includes a cap layer 140 between the buffer layer 104 and thefirst semiconductor layer 106. The cap layer 140 has a thickness T thatis greater than the thickness of the buffer layer 104. The cap layer 140comprises III-V compound semiconductor having an energy gap smaller thanthat of the material of the buffer layer 104. In an embodiment, the caplayer 140 comprises gallium nitride (GaN). Specifically, the cap layer140 covers the buffer layer 104, and a portion of the cap layer 140 islocated in the recess 111. The cap layer 140 includes a top surface 1401opposite to the buffer layer 104, and the thickness T of the cap layer140 refers to the shortest distance between the first portion 1042 ofthe top surface 1041 and the top surface 1401. In one embodiment, thecap layer 140 has a thickness T greater than 1 μm; in anotherembodiment, T is not more than 3.5 μm; and still in another embodiment,T is between 1 μm and 2 μm. In an embodiment, the cap layer 140 does notinclude dopants that are intentionally doped. Specifically, the dopingconcentration of the cap layer 140 is not more than 5×10¹⁷/cm³, and inone embodiment, not more than 1×10¹⁷/cm³. In this embodiment, since theplurality of protrusions 102 c is formed on the surface 102 a of thesubstrate structure 102 and the height of the protrusions 102 c is notmore than 1.5 μm, the cap layer 140 of the light-emitting device 100 isthinner than that of the conventional light-emitting device, yet thelight-emitting device 100 has the same performance as the conventionallight-emitting device. Therefore, the light-emitting device 100 in theembodiment has an advantage of being small in size.

FIGS. 2A and 2B show a light-emitting device 200 in accordance withanother embodiment of the present application. As shown in FIG. 2A, thelight-emitting device 200 includes a substrate structure 202, a bufferlayer 204 formed on the substrate structure 202, a cap layer 240 formedon the buffer layer 201, a first semiconductor layer 206 formed on thecap layer 240, a light emitting structure 208 formed on the firstsemiconductor layer 206 and a second semiconductor layer 210 formed onthe light emitting structure 208. The first semiconductor layer 206, thelight emitting structure 208 and the second semiconductor layer 210include III-V compound semiconductor, such as aluminum gallium indiumnitride (In_(x)Al_(y)Ga_(1-x-y)N, 0≤x≤1, 0≤y≤1). The light emittingstructure 208 includes a single heterostructure (SH), a doubleheterostructure (DH), a double-side double heterostructure (DDH), or amulti-quantum well structure, MQW). As shown in FIG. 2A, the directionT1 indicates the growth direction of the light emitting structure 208.The light emitting structure 208 generates radiation. In thisembodiment, the radiation includes light. The light can be visible orinvisible. The light has a dominant wavelength between 250 nm and 500nm. In this embodiment, the light-emitting device 200 includes a firstelectrode 220 and a second electrode 230. The first electrode 220 isformed on the first semiconductor layer 206 and electrically connects tothe first semiconductor layer 206. The second electrode 230 is formed onthe second semiconductor layer 206 and electrically connects to thesecond semiconductor layer 206.

Referring to FIG. 2B and FIG. 2A, FIG. 2B is a partially enlarged viewof the substrate structure 202 of FIG. 2A. The substrate structure 202includes a base portion 202 b and a plurality of protrusions 202 c. Thebase portion 202 b has a surface 202 a. In one embodiment, the thicknessof the base portion 202 b is not less than 100 μm; in anotherembodiment, the thickness of the base portion 202 b is not more than 300μm. The plurality of protrusions 202 c is arranged in a two-dimensionalarray on the surface 202 a of the base portion 202 b, and thearrangement of the plurality of protrusions 202 c can be regular orirregular. In the embodiment, each protrusion 202 c is integrated withthe base portion 202 b. Specifically, each protrusion 202 c and the baseportion 202 b have the same material such as sapphire, and the surface202 a is c-plane which is suitable for epitaxial growth. Thethree-dimensional shape of the protrusion 202 c includes a dome, a cone,or a pyramid. The cone includes a truncated cone and the pyramidincludes a polygonal pyramid or a truncated pyramid. In the embodiment,the three-dimensional shape of the protrusion 202 c is a cone and theprotrusion 202 c is substantially triangular in the cross-sectional viewof the light-emitting device. The buffer layer 204 is conformally formedon the plurality of protrusion 202 c and the surface 202 a.Specifically, the buffer layer 204 has a top surface 2041 opposite tothe base portion 202 b. The top surface 2041 includes a first portion2042 and a second portion 2043 connected to the first portion 2042. Thefirst portion 2042 covers the surface 202 a. The second portion 2043covers the plurality of protrusions 202 c. In the cross-sectional viewof the light-emitting device, a recess 211 is formed between the firstportion 2042 and the second portion 2043. In one embodiment, the bufferlayer 204 comprises aluminum nitride (AlN). The thickness of the bufferlayer 204 is greater than 5 nm; in another embodiment, the thickness ofthe buffer layer 204 is not more than 50 nm; and still in anotherembodiment, the thickness of the buffer layer 204 is between 10 nm and30 nm (both inclusive). If the thickness of the buffer layer 204 is lessthan 5 nm, the defect density of the epitaxial layers subsequently grownthereon (e.g. the first semiconductor layer 206) becomes high and theepitaxial quality of the light-emitting device is disrupted. If thethickness of the buffer layer 104 is more than 50 nm, for example, anAlN buffer layer with a thickness of more than 50 nm, the dominantwavelengths of the plurality of light-emitting devices epitaxially grownon the same wafer are inconsistent with each other. As shown in FIG. 2B,an included angle θ is between the surface 202 a and the side surface ofone protrusion 202 c or each of the protrusions 102 c. In oneembodiment, θ is not greater than 65 degrees; in another embodiment, θis not more than 55 degrees; and still in another embodiment, θ isbetween 30 and 65 degrees (both inclusive). In one embodiment, twoincluded angles θ are between the surface 202 a and the side surface ofone protrusion 202 c or each of the protrusions 202 c and θ are notgreater than 65 degrees. In one embodiment, θ are not greater than 55degrees. In another embodiment, θ are between 30 and 55 degrees (bothinclusive). In one embodiment, the two included angles θ of oneprotrusion 202 c or the two included angles θ of each protrusion 202 chave the same degrees or different degrees. Each protrusion 202 c has aheight H and a bottom width W. In the present embodiment, the height His not more than 1.5 μm. In another embodiment, the height H is between0.5 μm and 1.5 μm (both inclusive). The bottom width W is not less than1 and in another embodiment, the bottom width W is between 1 μm and 3 μm(both inclusive). In one embodiment, the ratio of the height H to thebottom width W is greater than 0 and not more than 0.5. In anotherembodiment, the ratio of the height H to the bottom width W is between0.4 and 0.5 (both inclusive). As shown in the figures, the arrangementof the protrusions 202 c has a period P. In one embodiment, theprotrusion 202 c has a vertex, and the vertex is the part of theprotrusion 202 c which is closest to the light-emitting structure 208along the direction T1. The period P is defined as the distance betweenthe vertices of two adjacent protrusions 202 c. In this embodiment, thecross-section of the protrusion 202 c is substantially triangular, andthe period P is between 1 μm and 3 μm (both inclusive). In oneembodiment, the height H=1.2 μm±10%; the bottom width W=2.6 μm±10%; theperiod P=3.0 μm±10%. In another embodiment, the height H=0.9 μm±10%; thewidth W=1.6 μm±10%; the period P=1.8 μm±10%. In another embodiment, H=1μm±10%; W=1.5 μm 10%; P=1.8 μm±10%. In another embodiment, the heightH=1.2 μm±10%, the width W=2.6 μm±10%; and the period P=3.0 μm±10%. Inone embodiment, XRD analysis is used to investigate the materialcharacteristics of the epitaxy layers of the light-emitting device 200.The light-emitting device 200 has a FWHM value of smaller than 250arcsec in accordance with a (102) XRD rocking curve. In one embodiment,the FWHM value is not smaller than 100 arcsec. Light emitted from thelight-emitting structure 208 is reflected and/or refracted due to theplurality of protrusions 202 c formed on the surface 202 a of thesubstrate structure 202 so that the light emitting efficiency of thelight-emitting device 200 is improved. Moreover, because of thesubstrate structure 202 coupled with the buffer layer 204 in accordancewith the present embodiment, the quality of the semiconductor layers andthe light-emitting structure 208 grown thereon is improved.

As shown in FIG. 2A, a method for fabricating a light-emitting device200 in accordance with an embodiment of the present applicationincludes: providing a substrate structure 202 including the base portion202 b and the plurality of protrusions 202 c formed thereon, wherein thebase portion 202 b has a surface 202 a. The plurality of protrusions 202c is arranged in a two-dimensional array on the surface 202 a of thebase portion 202 b, and the arrangement of the plurality of protrusions202 c can be regular or irregular. A buffer layer 204 is formed on thesurface 202 a of the base portion 202 b and covers the protrusions 202c. The buffer layer 204 comprises aluminum nitride (AlN). In oneembodiment, the method of fabricating the substrate structure 202includes providing a substrate (not shown) having a top surface and thenperforming a patterning step including removing a portion of thesubstrate from the top surface of the substrate to form the base portion202 b and the plurality of protrusions 202 c spaced apart with eachother on the base portion 202 b. The base portion 202 b has the surface202 a. The method of removing the portion of substrate includes dryetching or wet etching. In this embodiment, the protrusion 202 c issubstantially triangular in the cross-sectional view of thelight-emitting device 200. A method of forming a buffer layer 204includes physical vapor deposition (PVD). The method of fabricating thelight-emitting device 200 includes forming the first semiconductor layer206, the light-emitting structure 208, and the second semiconductorlayer 210 by metal organic chemical vapor deposition (MOCVD). The methodof performing epitaxial growth includes, but is not limited to, MOCVD,hydride vapor phase epitaxial (HVPE), or liquid-phase epitaxy (LPE).

As shown in FIG. 2A, in the present embodiment, the light-emittingdevice 200 further includes a cap layer 240 between the buffer layer 204and the first semiconductor layer 206. The cap layer 240 has a thicknessT that is greater than the thickness of the buffer layer 204. The caplayer 240 comprises III-V compound semiconductor having an energy gapsmaller than that of the material of the buffer layer 204. In anembodiment, the cap layer 240 includes gallium nitride (GaN).Specifically, the cap layer 240 covers the buffer layer 204, and aportion of the cap layer 240 is located in the recess 211. The cap layer240 includes a top surface 2401 opposite to the buffer layer 204, andthe thickness T of the cap layer 240 refers to the shortest distancebetween the first portion 2042 and the top surface 2401. In oneembodiment, the thickness T of the cap layer 240 is greater than 1 μm.In one embodiment, the thickness T of the cap layer 240 is not greaterthan 3.5 μm. In one embodiment, the thickness T of the cap layer 240ranges from 1 μm to 2 μm. In one embodiment, the cap layer 240 includesimpurities that are not intentionally doped. Specifically, the impurityconcentration of the cap layer 140 is not more than 5×10¹⁷/cm³. Inanother embodiment, the impurity concentration of the cap layer 140 notmore than 1×10¹⁷/cm³. In this embodiment, since the plurality ofprotrusions 202 c is formed on the surface 202 a of the substratestructure 202 and the height of the protrusions 202 c is not more than1.5 μm, the cap layer 240 of the light-emitting device 200 is thinnerthan that of the conventional light-emitting device, yet thelight-emitting device 200 has the same performance as the conventionallight-emitting device. Therefore, the light-emitting device 200 in theembodiment has an advantage of being small in size.

FIGS. 3A and 3B show another embodiment of a light-emitting device 300of the present application. As shown in FIG. 3A, the light-emittingdevice 300 includes a substrate structure 302, a buffer layer 304 formedon the substrate structure 302, a first semiconductor layer 306 formedon the buffer layer 304, a light emitting structure 308 formed on thefirst semiconductor layer 306 and a second semiconductor layer 310formed on the light emitting structure 308. The first semiconductorlayer 306, the light emitting structure 308, and the secondsemiconductor layer 310 include III-V compound semiconductor, such asaluminum gallium indium nitride (In_(x)Al_(y)Ga_(1-x-y)N, 0≤x≤1, 0≤y≤1).The light emitting structure 308 includes a single heterostructure (SH),a double heterostructure (DH), a double-side double heterostructure(DDH), or a multi-quantum well structure, MQW). As shown in FIG. 3A, thedirection T1 indicates the growth direction of the light emittingstructure 308. The light emitting structure 308 generates radiation. Inthis embodiment, the radiation includes light. The light can be visibleor invisible. The light has a dominant wavelength between 250 nm and 500nm. The light-emitting device 300 further includes a first electrode 320and a second electrode 330. The first electrode 320 is formed on thefirst semiconductor layer 306 and electrically connects to the firstsemiconductor layer 306. The second electrode 330 is formed on thesecond semiconductor layer 306 and electrically connects to the secondsemiconductor layer 306.

Referring to FIG. 3B and FIG. 3A, FIG. 3B is a partially enlarged viewof the substrate structure 302 of FIG. 3A. The base portion 302 b has asurface 302 a. In one embodiment, the thickness of the base portion 302b is not less than 100 μm. In another embodiment, the thickness of thebase portion 302 b is not more than 300 μm. The plurality of protrusions302 c is arranged in a two-dimensional array on the surface 302 a of thebase portion 302 b, and the arrangement of the plurality of protrusions302 c can be regular or irregular. Each protrusion 302 c includes afirst portion 302 d and a second portion 302 e on the first portion 302d. The first portion 302 d is integrated with the base portion 302 b andthe second portion 302 e is formed on the first portion 302 d.Specifically, the first portion 302 d includes a first material that isthe same as the material of the base portion 302 b. The second portion302 e includes a second material that is different from the firstmaterial. In the embodiment, the refractive index of the second materialis smaller than the refractive index of the first material.Specifically, the refractive index of the second material of the secondportion 302 e at the dominant wavelength is smaller than the refractiveindex of the first material of the first portion 302 d at the dominantwavelength. In one embodiment, in terms of the dominant wavelength, thedifference between the refractive index of the second material of thesecond portion 302 e and the refractive index of the first material ofthe first portion 302 d is greater than 0.1; in another embodiment, thedifference is greater than 0.15; and still in another embodiment, thedifference is between 0.15 and 0.4 (both inclusive). Thethree-dimensional shape of the protrusion 302 c includes a dome, a cone,or a pyramid. The cone includes a truncated cone and the pyramidincludes a polygonal pyramid or a truncated pyramid. In the embodiment,the three-dimensional shape of the protrusion 302 c is a cone and theprotrusion 302 c is substantially triangular in the cross-sectionalview. The material of the second portion 302 e can be silicon dioxide(SiO₂). The material of the first portion 302 d and the base portion 302b can be sapphire, and the surface 302 a is c-plane which is suitablefor epitaxial growth. The buffer layer 304 is conformably formed on theplurality of protrusion 302 c and the surface 302 a. In one embodiment,the buffer layer 304 comprises aluminum nitride (AlN). In oneembodiment, the thickness of the buffer layer 304 is greater than 5 nm;in another embodiment, the thickness is not more than 50 nm; and stillin another embodiment, the thickness is between 10 nm and 30 nm (bothinclusive). If the thickness of the buffer layer 304 is less than 5 nm,the defect density of the epitaxial layers (e.g. the first semiconductorlayer 306) subsequently grown thereon becomes high and the epitaxialquality of the light-emitting device is disrupted. If the thickness ofthe buffer layer 304 is more than 50 nm, for example, an AlN bufferlayer with a thickness of more than 50 nm, the dominant wavelengths ofthe plurality of light-emitting devices epitaxially grown on the samewafer are inconsistent with each other. As shown in FIG. 3B, an includedangle θ is between the surface 302 a and the side surface of oneprotrusion 302 c or each of the protrusions 302 c. In one embodiment, θis not greater than 65 degrees; in another embodiment, θ is not morethan 55 degrees; and still in another embodiment, θ is between 30 and 65degrees (both inclusive). In one embodiment, two included angles θ arebetween the surface 302 a and the side surface of one protrusion 302 cor each protrusion 302 c and θ are not greater than 65 degrees; inanother embodiment, θ are not greater than 55 degrees; and still inanother embodiment, θ are between 30 and 55 degrees (both inclusive). Inone embodiment, the two included angles θ of one protrusion 302 c or thetwo included angles θ of each protrusion 302 c have the same degrees ordifferent degrees. Each of the protrusions 302 c has a height H and abottom width W. In one embodiment, the ratio of the height H to thebottom width W is greater than 0 and not more than 0.5. In oneembodiment, the ratio of the height (H1) of the first portion 302 d ofone or of each protrusions 302 c to the height (H) of the protrusion 302c ranges between 1% and 30% (both inclusive). In another embodiment, theratio of the height (H1) of the first portion 302 d of one or of eachprotrusion 302 c to the height (H) of the protrusion 302 c rangesbetween 10% and 30% (both inclusive). As shown in the figures, thearrangement of the protrusions 302 c has a period P. In one embodiment,the protrusion 302 c has a vertex, and the vertex is the part of theprotrusion 302 c which is closest to the light emitting structure 308along the direction T1. The period P is defined as the distance betweenthe vertices of two adjacent protrusions 302 c. In this embodiment, thecross-section of the protrusion 302 c is substantially triangular, andthe period P is between 1 μm and 3 μm (both inclusive). In oneembodiment, the height H=1.2 μm±10%; the bottom width W=2.6 μm±10%; theperiod P=3.0 μm±10%. In another embodiment, the height H=0.9 μm±10%; thewidth W=1.6 μm±10%; the period P=1.8 μm±10%. In another embodiment, H=1μm±10%; W=1.5 μm±10%; P=1.8 μm 10%. In another embodiment, the heightH=1.2 μm±10%, the width W=2.6 μm±10%; and the period P=3.0 μm±10%. Inone embodiment, XRD analysis is used to investigate the materialcharacteristics of the epitaxy layers of the light-emitting device 300.The light-emitting device 300 has a FWHM value of smaller than 250arcsec in accordance with a (102) XRD rocking curve. In one embodiment,the FWHM is not smaller than 100 arcsec.

As shown in FIG. 3A, a method for fabricating a light-emitting device300 in accordance with an embodiment of the present applicationincludes: providing a substrate structure 302 including the base portion302 b and the plurality of protrusions 302 c formed thereon, whichincludes providing a substrate (not shown) having a top surface (notshown), and then performing a patterning step to form the base portion302 b and the plurality of protrusions 302 c space apart from each otheron the base portion 302 b. The patterning step includes forming aprecursor layer (not shown) on the top surface of the substrate by, forexample, physical vapor deposition (PVD), and then removing a portion ofthe precursor layer and a portion of the substrate from the top surface.The method of removing the portion of the precursor layer and theportion of the substrate includes dry etching or wet etching. Theportion of the precursor layer and the portion of the substrate areremoved to form the based portion 302 b with the surface 302 a and theother portions of the precursor layer and the substrate kept on baseportion 302 b form the plurality of protrusions 302 c separated fromeach other. In the embodiment, the protrusion is substantiallytriangular in a cross-sectional view. The plurality of protrusions 302 cis arranged in a two-dimensional array on the surface 302 a of the baseportion 302 b, and the arrangement of the plurality of protrusions 302 ccan be regular or irregular. The method for fabricating thelight-emitting device 300 in accordance with an embodiment of thepresent application includes forming the buffer layer 304 on the surface302 a of the base portion 302 b and covering the protrusions 302 c. Thebuffer layer 304 comprises aluminum nitride (AlN). The method of forminga buffer layer 304 includes physical vapor deposition (PVD). The methodof fabricating the light-emitting device 300 further includes formingthe first semiconductor layer 306, the light-emitting structure 308, andthe second semiconductor layer 310 by epitaxial growth such as metalorganic chemical vapor deposition (MOCVD). The method of pitaxial growthincludes, but is not limited to, MOCVD, hydride vapor phase epitaxial(HVPE), or liquid-phase epitaxy (LPE).

As shown in FIG. 3A, the light-emitting device 300 includes a cap layer340 between the buffer layer 304 and the first semiconductor layer 306.The cap layer 340 has a thickness T that is greater than the thicknessof the buffer layer 304. The cap layer 340 comprises III-V compoundsemiconductor having an energy gap smaller than that of the material ofthe buffer layer 304. In an embodiment, the cap layer 340 comprisesgallium nitride (GaN). Specifically, the cap layer 340 covers the bufferlayer 304, and a portion of the cap layer 340 is located in the recess311. The cap layer 340 includes a top surface 3401 opposite to thebuffer layer 304, and the thickness T of the cap layer 340 refers to theshortest distance between the first portion 3042 of and the top surface3401. In one embodiment, the cap layer 340 has a thickness T greaterthan 1 μm; in another embodiment, the thickness T of the cap layer 340is not more than 3.5 μm; and still in another embodiment, the thicknessT of the cap layer 340 is between 1 μm and 2 μm. In an embodiment, thecap layer 340 includes impurities that are not intentionally doped.Specifically, the impurity concentration of the cap layer 340 is notmore than 5×10¹⁷/cm³, and in one embodiment, not more than 1×10¹⁷/cm³.In this embodiment, since the plurality of protrusions 302 c is formedon the surface 302 a of the substrate structure 302 and the height ofthe protrusions 302 c is not more than 1.5 μm, the cap layer 340 of thelight-emitting device 300 is thinner than that of the conventionallight-emitting device, yet the light-emitting device 300 hassubstantially the same performance as the conventional light-emittingdevice. Therefore, the light-emitting device 300 in the embodiment hasan advantage of being small in size.

FIGS. 4A and 4B show top views of different embodiments of the substratestructure 102 of the light-emitting device in the present application.As shown in FIG. 4A, the surface 102 a of the base portion 102 b of thesubstrate structure 102 has a plurality of protrusions 102 c havingcircular contours in the top view, and the plurality of protrusions 102c can be arranged in a hexagonal repeating pattern. As shown in FIG. 4B,a plurality of protrusions 102 c are formed on the surface 102 a of thebase portion 102 b of the substrate structure 102. Each protrusion 102 chas a triangular contour in the top view, and one of the edges of eachtriangular contour can be a curve. The plurality of protrusions 102 ccan be arranged in a hexagonal repeating pattern.

FIGS. 5A and 5B show cross-sectional views of different embodiments ofthe protrusion of the substrate structure of the light-emitting devicein the present application. As shown in FIG. 5A, the protrusion 102 c issubstantially a trapezoid. Specifically, the protrusion 102 c has anupper plane P1 and a lower plane P2 opposite to the upper plane P1, andthe lower plane P2 is closer to the surface 102 a of the base portion102 b than the upper plane P1. In one embodiment, the ratio of an areaof the upper plane P1 to an area of the lower plane P2 is greater thanzero and not more than 0.3. In one embodiment, as shown in FIG. 4B andFIG. 5A, the three-dimensional shape of the protrusion 102 c is atruncated triangular pyramid. In the top view, the triangular contour ofthe lower plane P2 surrounds the triangular contour of the upper planeP1. Three inclined surface S are respectively formed between each edgeof the triangle of P2 and each edge of the triangle of the upper planeP1. In the embodiment, the period P is defined as the shortest distancebetween the centers of the planes P1 of the two adjacent protrusions 102c.

As shown in FIG. 5B, the protrusion 102 c includes an arc 1021 whichprotrudes outward, and two ends of the arc 1021 are connected to form apseudo chord 1022. The protrusion 102 c includes a top portion 201connecting to the arc 1021. In the embodiment, the maximum distance Bbetween the arc 1021 and the chord 1022 is greater than 0 μm, and inanother embodiment, not greater than 0.5 μm. The width D of the topportion 201 of the protrusion 102 c is the maximum distance between anytwo points on the peripheral of the top portion 201. In one embodiment,the width D of the top 201 is zero. In another embodiment, the width Dof the top 201 is greater than zero. θ is an angle between the surface102 a and the chord 1022. In the present embodiment, the height H isgreater than 0 μm and not more than 1.5 μm.

It will be apparent to those having ordinary skill in the art thatvarious modifications and variations can be made to the devices inaccordance with the present disclosure without departing from the scopeor spirit of the disclosure. In view of the foregoing, it is intendedthat the present disclosure covers modifications and variations of thisdisclosure provided they fall within the scope of the following claimsand their equivalents.

What is claimed is:
 1. A light-emitting device, comprising: a substratestructure, comprising a base portion having a surface and a plurality ofprotrusions regularly formed on the base portion; a buffer layercovering the plurality of protrusions and the surface; and III-Vcompound semiconductor layers formed on the buffer layer; wherein one ofthe plurality of protrusions comprises a first portion and a secondportion formed on the first portion and the first portion is integratedwith the base portion; wherein the base portion comprises a firstmaterial and the first portion comprises the first material, wherein thefirst portion comprises a first side surface and the second portioncomprises a second side surface connecting the first side surface; andwherein the buffer layer is formed on and contacts the first sidesurface, the second side surface and the surface of the base portion. 2.The light-emitting device according to claim 1, wherein the secondportion comprises a second material which is different from the firstmaterial and a refractive index of the second material is smaller than arefractive index of the first material.
 3. The light-emitting deviceaccording to claim 1, wherein the first portion of one of the pluralityof protrusions has a height H1 and the one of the plurality ofprotrusions has a height H; wherein a ratio of H1 to H is between 1% and30% both inclusive.
 4. The light-emitting device according to claim 2,wherein the buffer layer comprises a third material which is differentfrom the second material.
 5. The light-emitting device according toclaim 4, wherein the buffer layer comprises aluminum nitride.
 6. Thelight-emitting device according to claim 2, wherein the second materialcomprises SiO₂.
 7. The light-emitting device according to claim 1,wherein the first material comprises sapphire and the surface is c-planeof the sapphire.
 8. The light-emitting device according to claim 1,wherein the first portion comprises a planar top and the second portionis formed on and contacts the planar top.
 9. The light-emitting deviceaccording to claim 1, wherein an arrangement of the plurality ofprotrusions has a period and the period is between 1 μm and 3 μm bothinclusive.
 10. The light-emitting device according to claim 1, whereinin a cross-sectional view, an included angle between a side surface ofone of the plurality of protrusions and the surface of the base portionis less than 65 degrees.
 11. The light-emitting device according toclaim 1, wherein a thickness of the buffer layer is greater than 5 nmand not more than 50 nm.
 12. The light-emitting device according toclaim 1, wherein a three-dimensional shape of one of the plurality ofprotrusions comprises a dome, a cone or a pyramid.
 13. Thelight-emitting device according to claim 1, wherein in a cross-sectionalview, one of the plurality of protrusions comprises an arc whichprotrudes outward, and two ends of the arc are connected to form apseudo chord; and wherein a maximum distance between the arc and thepseudo chord is greater than 0 μm and not greater than 0.5 μm.
 14. Thelight-emitting device according to claim 1, wherein the buffer layer isconformably formed on the first side surface, the second side surfaceand the surface of the base portion.